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Forward hot extrusion forming process of 4-lobe aluminum alloy helical surface rotor

四叶铝合金螺旋面转子正向热挤压成形工艺研究

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Abstract

The 4-lobe aluminum alloy helical surface rotors are widely applied in industry, such as superchargers. Generally, the conventional manufacturing processes of aluminum alloy helical surface are time consuming and costly. To make the manufacturing processes more flexible and economical, the forward hot extrusion process is proposed to form the 4-lobe aluminum alloy helical surface rotors. In this work, we implement both simulations and experiments to the forming process of the helical surface, of which the material is 6063 aluminum alloy. The forward hot extrusion process is simulated with finite element method in DEFORM-3D. Based on the simulation method, the influences of different extrusion parameters, such as extrusion temperature, extrusion speed and extrusion ratio, on the extrusion process are studied. According to the numerical simulation results, the optimal case is chosen to carry out the experiment. Furthermore, the experimental results show that the surface is smooth; the toothed fill is full; the twist angle in the length direction is evenly distributed; the value of twist angle is roughly in line with the design angle, which is mainly due to the modified die structure, having a positive and significant effect on the increment of twist angle. Therefore, the twist angle has an increase of about 76%, which verifies the modified die structure.

摘要

四叶铝合金螺旋面转子广泛应用于工业中, 如机械增压器。传统加工铝合金螺旋面的工艺存在 费时和成本高的问题。为了使制造工艺更加灵活和经济, 提出了正向热挤压工艺来成形 4 叶铝合金螺 旋面转子。本文所用的材料为 6063 铝合金, 对螺旋面的成形过程进行了数值仿真和挤压实验。采用 DEFORM-3D 软件对正向热挤压成形过程进行了有限元模拟。在仿真方法的基础上, 研究了不同的挤 压参数, 如挤压温度、挤压速度、挤压比, 对挤压过程的影响。根据数值模拟结果, 选择最优情况进 行挤压实验。实验结果表明, 转子表面光滑;齿形填充饱满;在长度方向上扭转角分布均匀;扭转角 的值与设计角的值基本一致。能够达到这个好结果的主要原因是使用了改进后的模具结构, 对扭转角 的增加有积极而显著的影响, 因此, 扭转角增加了约76%, 验证了改进后模具结构。

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Authors and Affiliations

  1. School of Mechanical and Electrical Engineering, Central South University, Changsha, 410083, China

    Feng Xia  (夏峰), Hui Li  (李辉), Hou-gen Liu  (刘厚根) & Bei-bei Zhao  (赵贝贝)

  2. Kingle Aluminum Technology Stock Co., Ltd, Changsha, 410126, China

    Zhao-qiang Zhang  (张昭强), Di-hua Lu  (陆地华) & Jian-qiang Chen  (陈建强)

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  1. Feng Xia  (夏峰)
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  2. Hui Li  (李辉)
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  3. Hou-gen Liu  (刘厚根)
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  4. Bei-bei Zhao  (赵贝贝)
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  5. Zhao-qiang Zhang  (张昭强)
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  6. Di-hua Lu  (陆地华)
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  7. Jian-qiang Chen  (陈建强)
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Corresponding author

Correspondence to Hou-gen Liu  (刘厚根).

Additional information

Foundation item: Project(zzyjkt2014-09) supported by the National Key Laboratory of High Performance and Complex Manufacturing, China; Project(2015GK3006) supported by Key R&D Program of Science and Technology Department of Hunan Province, China

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Xia, F., Li, H., Liu, Hg. et al. Forward hot extrusion forming process of 4-lobe aluminum alloy helical surface rotor. J. Cent. South Univ. 26, 2307–2317 (2019). https://doi.org/10.1007/s11771-019-4175-7

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  • DOI: https://doi.org/10.1007/s11771-019-4175-7

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